Covering structure having automatic coupling system

ABSTRACT

A tonneau system for a cargo box of a vehicle having a support frame connectable to the cargo box. A cover spans the support frame and is positionable between a tensioned position and an untensioned position. A bow member is coupled to the cover and is moveable between a first position and a second position in response to the movement of the cover between the tensioned position and the untensioned position. A retaining member is then operably coupled to the support frame. The retaining member retains the bow member when the bow member is in the first position and releases the bow member when the bow member is in the second position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.10/826,079 filed on Apr. 16, 2004. The disclosure of the aboveapplication is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to coverings for pickup trucksand, more particularly, relates to a roll up tonneau cover system.

BACKGROUND OF THE INVENTION

Tonneau covers have been used for a number of years to cover the cargobox of pickup trucks against dirt, debris, and other environmentalcontaminants and to improve the aesthetic quality thereof. Currenttonneau covers often employ a VELCRO® hook-and-loop fastening systemoperably coupled between a soft tarp of the tonneau cover and thesidewalls of the cargo box of the pickup truck. This arrangement permitsthe tarp to be coupled to the cargo box to conceal the contents thereofor, alternatively, to be rolled up to reveal the contents of the cargobox of the pickup truck. The VELCRO® has disadvantages of wearing overtime, pulling, and not allowing the fabric to move freely, which mayresult in a puckered and wrinkled appearance.

A series of bows are typically coupled to the tarp and span the width ofthe cargo box. These bows serve to support and minimize accumulation ofdirt, debris, and other environmental contaminants from collecting ontop of the tarp. When the tarp is rolled up, these bows are oftenenclosed within the tarp bundle.

Typically, these bows are cylindrical in cross-section and the endsthereof rest upon rails fixed to longitudinal sidewalls of the cargo boxof the pickup truck. However, often times these bows fail to minimizethe lifting action caused by aerodynamic forces during vehicle travel.That is, conventional soft or roll-up type tonneau covers often sufferfrom flapping at highway speeds, which can lead to premature failure.

Accordingly, there exists a need in the relevant art to provide atonneau cover system capable of overcoming the aerodynamic liftingforces caused during vehicle travel. Additionally, there exists a needin the relevant art to provide a tonneau cover system capable ofreliably coupling the tonneau cover to the vehicle at variouslongitudinal locations. Still further, there exists a need in therelevant art to provide a tonneau cover system capable of overcoming thedisadvantages of the prior art.

SUMMARY OF THE INVENTION

According to the principles of the present invention, a tonneau systemfor a cargo box of a vehicle having an advantageous construction isprovided. The tonneau cover system includes a support frame connectableto the cargo box. A cover spans the support frame and is positionablebetween a tensioned position and an untensioned position. A bow memberis coupled to the cover and is moveable between a first position and asecond position in response to the movement of the cover between thetensioned position and the untensioned position. A retaining member isthen operably coupled to the support frame. The retaining member retainsthe bow member when the bow member is in the first position and releasesthe bow member when the bow member is in the second position.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a perspective view illustrating a pickup truck having atonneau cover system according to the principles of the presentinvention;

FIG. 2 is a perspective view illustrating the pickup truck having thetonneau cover system according to the principles of the presentinvention with portions removed for clarity;

FIG. 3 is a cross sectional view illustrating the head rail assemblytaken along line 3—3 of FIG. 1;

FIG. 4 is an enlarged perspective view illustrating the adjustment beammechanism;

FIG. 5 is an enlarge perspective view illustrating the rear frame railassembly;

FIG. 6 is a perspective view illustrating the pickup truck having thetonneau cover system with portions removed for clarity and the rearframe rail assembly in a raised position;

FIG. 7 is an enlarged perspective view illustrating the bow member andretaining bracket;

FIG. 8 is a side view illustrating the bow member and retaining blockmember in a released position;

FIG. 9 is a side view illustrating the bow member and retaining blockmember in a retained position;

FIG. 10 is an enlarged perspective view illustrating the retaining blockmember;

FIG. 11 is an enlarged perspective view illustrating the bow member inthe retained position;

FIG. 12 is an enlarged perspective view illustrating the bow member inthe released position;

FIG. 13 is a cross section view illustrating the tonneau cover system ofthe present invention in the retained position employing a retainingbracket; and

FIG. 14 is a cross section view illustrating the tonneau cover system ofthe present invention in the released position employing a retainingblock member.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiments is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

With reference to FIGS. 1 and 2, a pickup truck 10 is shown having aroll up tonneau system 12 which is attached to a cargo box 13 accordingto the present invention. Cargo box 13 has a front wall 14, a leftsidewall 16, a right sidewall 18, and a rear wall or tailgate 20. Rollup tonneau system 12 includes a flexible, stretchable fabric cover 22that is drawn tightly over a substantially rigid rail support system 24and removably attached to rail support system 24. Rail support system 24is comprised of a number of frame rails that are attached to one anotherto form a rectangular frame. The frame rails included are a front framerail or head rail assembly 26, a left side frame rail assembly 28, aright side frame rail assembly 30, and a rear frame rail assembly 32.Rail support system 24 is aligned with and coupled to the top ofsidewalls 16 and 18 of cargo box 13 as well as the top of front wall 14and tailgate 20, according to one of many methods. A clamping system orfastening system may be used to fasten the rail assemblies 26, 28, 30,and 32 to the sidewalls 16 and 18 of pickup truck 10. An example of aclamping system can be found in commonly-assigned U.S. patentapplication Ser. No. 10/331,711, entitled “Roll Up Tonneau CoverSystem.” The disclosure of this application is incorporated herein byreference. Stretchable fabric cover 22 is support cross-vehicle via aplurality of cross bows 301, which each selectively engage correspondingretaining members coupled to left side frame rail assembly 28 and rightside frame rail assembly 30, which will be discussed in detail below.

It should be understood that right sidewall 18 and left sidewall 16 ofpickup truck 10 and the corresponding right side frame rail assembly 30and left side frame rail assembly 28 are identical in construction, yetarranged in mirrored symmetry. Accordingly, in the interest of brevity,only one side will be discussed in detail below unless noted otherwise.

Still referring to FIGS. 1 and 2, right side frame rail assembly 30 iscoupled to right sidewall 18 of cargo box 13 of pickup truck 10. As canbe seen, sidewall 18 of cargo box 13 includes a generally horizontal topsurface 34 and a downwardly extending inside wall 36. However, it shouldbe appreciated that generally horizontal top surface 34 and downwardlyextending inside wall 36 may have any one of a number of configurations,which are dependent upon styling and functionality determined by thevehicle manufacturer. Hence, it should be understood that the particularshape of these surfaces/walls may vary, along with the specific shape ofthose corresponding components of frame rail assembly 30.

Turning now to FIG. 3, head rail assembly 26 will now be described indetail. As can be seen in the figure, head rail assembly 26 generallyincludes an extruded front bracket member 40. Extruded front bracketmember 40 is preferably made of a light-weight, corrosion resistantmaterial, such as aluminum. Extruded front bracket member 40 includes agasket channel 42 extending longitudinally along a forward portion 44 ofextruded front bracket member 40. Gasket channel 42 is sized to receivea corresponding channel feature 46 of a flexible gasket member 48 suchthat flexible gasket member 48 is coupled with and supported by extrudedfront bracket member 40. Gasket member 48 is positionable such that itengages and forms a fluid seal between a nose portion 50 of gasketmember 48 and front wall 14 of pickup truck 10. In this regard, waterand other environmental contaminants are prevented from entering cargobox 13 of pickup truck 10. During assembly, channel feature 46 offlexible gasket member 48 is slid into gasket channel 42.

Extruded front bracket member 40 further includes cover retaining slot52 extending longitudinally along forward portion 44 of extruded frontbracket member 40. Cover retaining slot 52 is sized to receive acorresponding rod member 54. Preferably, rod member 54 is receivedwithin a channel 56 sewn or otherwise formed in stretchable fabric cover22. In this regard, stretchable fabric cover 22 is reliably retained inconnection with extruded front bracket member 40. During assembly, rodmember 54 is first slid into channel 56 of stretchable fabric cover 22and the two are slid into cover retaining slot 52.

Still referring to FIG. 3, extruded front bracket member 40 furtherincludes a tip support 60 extending along forward portion 44. Tipsupport 60 is adapted to be received between a fold-back portion 62 ofstretchable fabric cover 22 and provides support to stretchable fabriccover 22. Tip support 60 permits stretchable fabric cover 22 to extendforward from extruded front bracket member 40 to bridge a gap betweenextruded front bracket member 40 and front wall 14 and to furtherconceal gasket member 48. Tip support 60 may be received within asupport channel 64 formed in extruded front bracket member 40. However,it should also be understood that tip support 60 may be integrallyformed with extruded front bracket member 40 or may be part of aseparate polymer extrusion to which the stretchable fabric cover 22 issewn. This extrusion would be slidably engaged with bracket member 40.

Referring now to FIGS. 3 and 4, tonneau system 12 further includes anadjustment beam mechanism 100 engagable with extruded front bracketmember 40. Adjustment beam mechanism 100 is provided for maintaining aconstant tensional force on stretchable fabric cover 22 to a desiredtightness. Adjustment beam mechanism 100 includes a cantilever beammember 102 having a first end 104 and a second end 106. First end 104 ofcantilever beam member 102 is fixedly mounted to extruded front bracketmember 40 via conventional fasteners 109 and a mounting bracket 110.Mounting bracket 110 is slidably engaged in slot 112 of extruded frontbracket member 40. Mounting bracket 110 is preferably sized to permitsimple positioning of mounting bracket 110 and cantilever beam member102 relative to extruded front bracket member 40 when the fasteners areloosened. However, on the other hand, mounting bracket 110 shouldpreferably frictionally engage flanges 114 when the fasteners aretightened.

As best seen in FIGS. 2–4, adjustment beam mechanism 100 furtherincludes a finger member 120, which is operably coupled to frame railassembly 30. Finger member 120 is sized to extend upward from frameassembly 30 in a generally L-shaped configuration. An end 122 of fingermember 120 is engagable with second end 106 of cantilever beam member102. Such engagement of finger member 120 against the biasing force ofcantilever beam member 102 cause extruded front bracket member 40 to beurged forward (relative to the vehicle) to draw stretchable fabric cover22 tightly over rail support system 24.

It should be understood that cantilever beam member 102 may be pre-bentto tailor a desired biasing force. It is generally desired thatadjustment beam mechanism 100 is disposed on each side of the vehiclebed to provide equal tensioning thereabout. Specifically, it is desiredthat adjustment beam mechanism 100 is arranged to provide about 15 to 10pounds of tensioning force on each side.

Turning now to FIG. 5, rear frame rail assembly 32 will be described indetail. Rear frame rail assembly 32 generally includes an extruded rearbracket member 200. Rear bracket member 200 is similar in constructionto front bracket member 40; however, rear bracket member 200 includes arounded bull nose portion 202. Rear bracket member 200 further includesa receiving channel 56′ for receiving rod member 54 coupled to fabriccover 22 similarly as mentioned above. Rear frame rail assembly 32 stillfurther includes a latching system, such as that described incommonly-assigned U.S. patent application Ser. No. 10/331,711, entitled“Roll Up Tonneau Cover System.”

With continued reference to FIG. 5, rounded bull nose portion 202 ofrear bracket member 200 is sized to be pivotally received within aconcave portion 204 of a corresponding rear pivot block 206. In thisregard, rear frame rail assembly 32 may pivot upward about the interfacebetween rounded bull nose portion 202 and concave portion 204 into araised position (see FIG. 6). In this raised position, the tension infabric cover 22 is released. However, in a lowered position, the tensionis then again exerted upon fabric cover 22 according to the biasingforce of adjustment beam mechanism 100. Rear pivot block 206 is fixedlycoupled to frame rail assembly 30 via conventional means, such asfasteners. It should be appreciated that as rear bracket member 200 islowered into a down position, fabric cover 22 is drawn rearward againstthe biasing force of adjustment beam mechanism 100. During thisoperation, fabric cover 22 is translated rearward a predetermineddistance. This translation distance will be used to affect additionalretaining features that will be described in detail below. During anopposition operation, namely the raising or pivoting of rear bracketmember 200 causes the tension in fabric cover 22 to be released, whichcauses fabric cover 22 to translate forward in response to the biasingforces of adjustment beam mechanism 100.

Still referring to FIG. 5, rear bracket member 200 further includes astrip member 212 extending along rearward portion 210. Strip member 212is adapted to be sewn into fabric cover 22 and provides support tostretchable fabric cover 22. Strip member 212 may be received within asupport channel 214 formed in rear bracket member 200. However, itshould also be understood that strip member 212 may be integrally formedwith rear bracket member 200.

Turning now to FIGS. 6 and 7, it can be seen that tonneau system 12further includes a retaining system 300 for retaining sections of fabriccover 22 located between head rail assembly 26 and rear frame railassembly 32. As best seen in FIG. 6, retaining system 300 includes aplurality of cross vehicle bow members 301 operably coupled with fabriccover 22 and engaging retaining brackets 302 fixedly coupled to framerail assembly 28, 30. Retaining brackets 302 may be of any shape ordesign; however, two possible configurations will be discussed herein.

With reference to FIGS. 6 and 7, retaining bracket 302 is illustrated asa generally sheet-like member shaped to define a generally planarsection 304 and a receiving section 306. Planar section 304 is disposedadjacent frame rail assembly 28, 30 and fastened thereto viaconventional means, such as fasteners. Receiving section 306, however,is shaped to receive a corresponding portion of vehicle bow member 301.That is, in the embodiment illustrated in FIGS. 6 and 7, vehicle bowmember 301 is generally cylindrical in cross-section. Accordingly,receiving section 306 is generally cylindrical, concave in shape toreadily receive and retaining vehicle bow member 301 therein. Receivingsection 306 extends upward to an end 308, which is positioned relativeto vehicle bow member 301 to generally prevent vehicle bow member 301from disengaging with retaining bracket 302 in a vertical direction.

Vehicle bow member 301 is generally cylindrical in cross-section.Vehicle bow member 301 may define an enclosed tubular member or may beconstructed of rolled aluminum, or other material. Preferably, vehiclebow member 301 further includes an optional paddle-shaped bow end 310extending outwardly from vehicle bow member 301. Paddle-shaped bow end310 overlaps a portion of frame rail assembly 28, 30. Paddle-shaped bowend 310 serves to push outwardly in a lateral direction (in thecross-vehicle direction) keeping the stretchable fabric cover 22 taunt.Paddle-shaped bow end 310 further biases the periphery of stretchablefabric cover 22 down to seal against frame rail assembly 28, 30. Framerail assembly 28, 30 have alternating high and low sections that act asa labyrinthian seal.

Alternatively, as seen in FIGS. 8–12, retaining bracket 302 may be madeas a block member, generally indicated at 302′. Retaining block member302′ is preferably made of a Nylon or other plastic material and isinjection molded. Retaining block member 302′ is preferably fastened toframe rail assembly 28, 30 via a fastener 303 extending through anaperture 350 formed in retaining block member 302′. Fastener 303 engagesa sliding bracket 305 received within frame rail assembly 28, 30.Retaining block member 302′ further includes a tab member 352 that issized to be slidably received within a channel 354 of frame railassembly 28, 30. Tab member 352 and channel 354 cooperate to prevent, orat least, minimize rotation of retaining block member 302′ to ensureproper positioning of retaining block member 302′. Retaining blockmember 302′ further includes a receiving section 356, which is shaped toreceive a corresponding portion of vehicle bow member 301. That is, inthe embodiment illustrated in FIGS. 8–12, vehicle bow member 301 isgenerally cylindrical in cross-section. Accordingly, receiving section356 is generally cylindrical, concave in shape to readily receive andretaining vehicle bow member 301 therein. Receiving section 356 extendsupward to an end 358, which is positioned relative to vehicle bow member301 to generally prevent vehicle bow member 301 from disengaging fromretaining block member 302′ in a vertical direction. More particularly,as seen in FIG. 10, end 358 may terminate at a single finger 360, ifdesired.

Turning now to FIGS. 13 and 14, it can be seen that vehicle bow member301 is engaged and retained within receiving section 356 when rearbracket member 200 is lowered (see FIG. 13), while conversely vehiclebow member 301 is released and free to be raised when bracket member 200is raised (see FIG. 14). It is worth noting that this operating isillustrated in FIGS. 13 and 14 in connection with retaining bracket 302and retaining block member 302′.

As best seen in FIGS. 8 and 9, vehicle bow member 301 is coupled tofabric cover 22 through a coupling system 400. Coupling system 400includes a rod or cord member 402 slidably received within a bow channel404 extending longitudinally through vehicle bow member 301. Cord member402 captures a portion 406 of fabric cover 22 simply by routing fabriccover 22 around cord member 402. The shape of bow channel 404 retainingcord member 402 therein, thereby preventing fabric cover 22 fromdisengaging from vehicle bow member 301. Most preferably, portion 406 offabric cover 22 is sewn into fabric cover 22 to prevent migration offabric cover 22 relative to cord member 402. It should be understoodthat this positive coupling of fabric cover 22 to vehicle bow member 301(and the corresponding coupling of vehicle bow member 301 to eitherretaining bracket 302 or retaining block member 302′) serves to retainand prevent rising of fabric cover 22 during vehicle travel.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

1. A method of latching a cover of a vehicle, said method comprising:providing a cover spanning at least a portion of a frame; providing abow member operably coupled to said cover and moveable therewith; andproviding a retaining member extending from said frame; tensioning saidcover thereby causing said bow member to engage said retaining member.2. The method according to claim 1 wherein said tensioning said covercomprises: providing a bracket member coupled to said cover; andpivoting said bracket member in a first direction such that saidpivoting applies a tensioning force to said cover translating said coverin a first direction and causing said bow member to engage saidretaining member.
 3. The method according to claim 2, furthercomprising: pivoting said bracket member in a second direction such thatsaid pivoting releases said tensioning force in said cover therebytranslating said cover in a second direction and causing said bow memberto disengage said retaining member.
 4. The method according to claim 1,further comprising: applying a biasing force to said cover to maintainsaid bow member in engagement with said retaining member.
 5. The methodaccording to claim 4 wherein said applying a biasing force to said covercomprises applying a biasing force to said cover via a cantilever memberfixedly coupled to said frame.
 6. The method according to claim 1wherein said tensioning said cover comprises: tensioning said coverthereby causing said bow member to engage within an arcuate receivingsection of said retaining member to retain said bow member againstgenerally vertical movement.
 7. The method according to claim 1, furthercomprising: resisting rotational movement of said bow member relative tosaid frame during said tensioning said cover.
 8. A method of latching atonneau cover of a vehicle, said method comprising: pivoting a bracketmember to a lowered position, said bracket member being coupled to acover, said cover being coupled to a bow member extending cross-vehicle,said pivoting of said bracket member applying a tensioning force to saidcover thereby translating said cover causing said bow member to operablyengage a retaining member coupled to the vehicle.
 9. The methodaccording to claim 8, further comprising: applying a biasing force tothe cover via a biasing member to maintain said tensioning force. 10.The method according to claim 8, further comprising: pivoting saidbracket member to a raised position to release said tensioning forcethereby translating said cover causing said bow member to disengage fromsaid retaining member.
 11. The method according to claim 8, furthercomprising: applying a biasing force to said cover to maintain said bowmember in engagement with said retaining member.
 12. The methodaccording to claim 11 wherein said applying a biasing force to saidcover comprises applying a biasing force to said cover via a cantilevermember.
 13. The method according to claim 8, further comprising:resisting rotational movement of said bow member about its axis duringsaid applying a tensioning force to said cover.
 14. A method ofassembling a tonneau cover of a vehicle, said vehicle having a cargobox, said method comprising: connecting a support frame to the cargobox; spanning a cover across at least a portion of said support frame,coupling a bow member to said cover for movement therewith; andtensioning said cover such that said cover translates said bow memberinto engagement with a retaining member.
 15. The method according toclaim 14 wherein said tensioning said cover comprises: providing abracket member coupled to said cover; and pivoting said bracket membersuch that said pivoting applies a tensioning force to said covertranslating said cover into engagement with said retaining member. 16.The method according to claim 14, further comprising: applying a biasingforce to said cover to maintain said bow member in engagement with saidretaining member.
 17. The method according to claim 16 wherein saidapplying a biasing force to said cover comprises applying a biasingforce to said cover via a cantilever member fixedly coupled to saidsupport frame.
 18. The method according to claim 14 wherein saidtensioning said cover comprises: tensioning said cover thereby causingsaid bow member to engage within an arcuate receiving section of saidretaining member to retain said bow member against generally verticalmovement.
 19. The method according to claim 14, further comprising:resisting rotational movement of said bow member relative to saidsupport frame during said tensioning said cover.